group exercise: case study of paint production practical... · group exercise: case study of paint...
TRANSCRIPT
Group Exercise: Case study of Paint Production
Bangkok, 1 March 2012
Reinhard Joas, BiPRO
Beratungsgesellschaft für integrierte Problemlösungen
2
Group Exercise:Case Study of Paint Producers
3
Awareness raising video “Blast Wave in Danvers”
Source: US Chemical Safety Board (CSB) http://www.csb.gov/videoroom
Solvent vapour explodes at CAI/Arnel ink and paint manufacturing facility.
Destroyed a neighbourhood: homes and businesses were damaged beyond repairLink to the upcoming interactive case based exercise
While watching, please attend to the following question:
How could Responsible Production and its tools have contributed to the prevention of this accident?
4
Introduction to integrative case based exercise
Formulation and application of paints
5
Tools for the first step of Responsible Production
1. Identify responsible production issues
UNDERSTAND THE PROCESS FLOW
RISK ASSESSMENT AND PRIORISATION
STANDARDS, CODES, LAW AND REGULATIONS
6
Tool 1.1Prepare process flow chart
Tool 1.2Chemical inventory and hazard classification
Tool 1.3Identify risks
Tool 1.4Hazard hotspots map
Tool 1.5Legal register
Tools for the first step of Responsible Production
7
Tool 1.1 Prepare a process flow diagram
Step 1: Prepare your process flow diagram
Define boundaries of process
Decision on level of detail to be included in the diagram
Identify steps and activities in the process
Describe sequence of activities
Discussion and revision of flowchart with relevant stakeholders
e.g. Workers and supervisors
Suppliers
Transporters
Customers
Maintenance companies
Waste transporters
8
You are invited to.....
Prepare a process flow diagram for formulation and application of paints
containing
Boundaries of process
Certain level of detail
Relevant steps and sequence of activities
Now it is your turn....
9
Process flow - Definition of boundaries of the process
Production of solvents
Production of pigments
Production of varnishes
storage storage storage
Formulation Non hazardous waste
Hazardous waste
disposal
disposaltransport ofproducts
storage
Re-packaging
storage
Application
Painted products
storage
storagetransport of solvents
Non hazardous waste
Hazardous waste
disposal
disposal
storage
storage
System boundaries
Transport of raw materials
Transport of raw materials
10
Storage pigments
Storage solvents
Storage varnishes
Chemicals
Solvents
Pigments
Varnishes
Level of detail to be included in the flow diagram - Formulation
Storage of final paint product
Formulation
Dosing and pre-mixing
Milling and dispersing (cooling)
Finishing and blending
Filling
Packaging
Transport of raw materials to company site
Transport
Transport of hazardous
wastes
11
Storage paints
Storage solvents
Chemicals
Solvents
Paint
Varnishes
Level of detail to be included in the flow diagram - Application
Application
Diluting
Blending
Application
Drying
Storage of other raw material
Painted product
Continuation of manufacturing of final product
Cleaning of equipment
Transport
Transport of hazardous
wastes
12
Identification of steps and sequence of activities in the process of formulation
Transport to company site
Off-loading and storage at company site
Steps during production process
Quality control, packaging
Dosing and pre-mixing
Milling and dispersing
Finishing and blending
Filling
Transport of final product,Transport of waste
Formulation
13
Identification of steps and sequence of activities in the process of application
Transport to company site
Off-loading and storage at company site
Steps during production process
Continuation of manufacturing of final
product
Application
Diluting
Blending
Application
Drying
Cleaning of equipment
14
Identification of chemicals and their quantities
Identification of hazards associated with activities such as potential for a fire or an explosion
This information is explained in Material Safety Data Sheets (MSDS); should be
made available by suppliers
Identification of hazards for all chemicals
Mark hazards on flow-chart
Repetition of this process through entire process flow-chart
Step 2: Identify the chemicals, their quantities and the hazards involved in the process
Tool 1.1 Prepare a process flow diagram
15
Next step......
Identify chemicals and their quantities
Potential hazards
forformulation and application of paints
.........it is again your turn....
16
Ap
plic
atio
nFo
rmu
lati
on
Identification of chemicals and quantities
Process steps at company site Chemicals involvedQuantity of chemicals,
e.g. t/a
Dosing and pre-mixing
Milling and dispersing
Finishing and blending
Filling
Diluting
Blending
Application
Drying
Cleaning of equipment
Varnishes, pigments
Varnishes, pigments, solvents
Paints
Paints
Solvents, paints
Solvents, paints
Solvents, paints
Solvents
Solvents
Transport
17
Identification of hazards for chemicals
Potential hazards
Ap
plic
atio
nFo
rmu
lati
on
Flammable properties, irritating effects
Sensitizing properties
Explosive and highly flammable properties
Harmful
Flammable properties
Danger for the environment
Chemicals involved
Varnishes
Pigments
Solvents
Paints
Solvents
Paints
Classifications
e.g. F, Xi
e.g. Xi
e.g. F+, E
e.g. Xn
e.g. F
e.g. N
Tran
spo
rt
18
Identification of hazards for processes
Process steps at company site Potential hazardsA
pp
licat
ion
Form
ula
tio
n
Dosing and pre-mixing
Milling and dispersing
Finishing and blending
Filling
Diluting
Blending
Application
Drying
Cleaning of equipment
Spills
Spills, exothermic reaction
Spills, exothermic reaction
Spills, leaking
Spills, leaking
Spills, exothermic reaction
Explosion
Explosion, burning
Spills
Tran
spo
rt
Spills, leaking
Tran
spo
rtTr
ansp
ort
Spill
sSp
ills
Spill
s
19
Identification of hazards for all chemicals
e.g. Material safety data sheets for solvents, pigments, varnishes, final paint product
20
Tool 1.3 Identify health, environmental, social and economic risks
Step 1: Create a risk assessment team Step 2: Review your hazard hotspots
Pay particular attention to areas or process steps where large quantities of hazardous chemicals may be stored or handled
Step 3: Identify risk-prone and vulnerable groups, areas and assets in case of an accident
Identification of threatened objects (people, environment and property) in case of accident
Step 4: Identify potential accident scenarios related to the hazard hotspots you have identified
Identification and analysis of past accidents in the sector
List potential accidents related to the Hazard Hotspots which have been already identified
Consider different accident scenarios
21
Continue to.....
Identify accident scenarios with
threatened objects and stakeholders
forformulation and application of paints
..........it is your third turn....
22
factory site (formulation)
Farmers, agricultural land
Other industrial
sites
Other factory
Road
CommunityProperties, citizens
Accident scenarios
Modelling of dispersion in case of accident
River
Storage pigments
Storage
solvents
Storage varnishes
Drinking water supply
Transport
23
Step 5: Identify the severity of related health, environmental, social and economic impact in an accident situation
Assign a ‘severity’ (importance) factor
Discussion and agreement in risk assessment team
Tool 1.3 Identify health, environmental, social and economic risks
Consider impact on
• Health of community and workers• Agriculture and fisheries• Water resources and quality of air• Site facilities and transport infrastructure• Community and social infrastructures• Company image
Scale should be adapted to both the country and the local context
1. Negligible 2. Limited 3. Serious 4. Very Serious 5. Catastrophic
24
Tool 1.3 Identify health, environmental, social and economic risks
Step 6: Estimate the likelihood of each of the identified accident situations actually taking place
1. Practically impossible2. Unlikely3. Rarely4. Regularly5. Frequently
Step 7: Assign a risk factor to each hazard hotspot
Assign each hazard hotspot a risk factor from 1/1 (lowest) to 5/5 (highest) Consider different possible hazard scenarios related to hot spots when
assigning risk factors Repeat this for each activity in the process Mark the risk factor on your flow chart
Step 8: Prioritise your hazards hotspots
25
Tool 1.3 Identify health, environmental, social and economic risks
26
Go on to......
Risk assessment and prioritisation
of
formulation and application
Assign risk factors (frequency/severity)
Prioritize the hazard hotspots
..........the final stretch is close......
27
Storage pigments Storage solvents Storage varnishes
Risk assessment and prioritisation - formulation
Storage of final paint product
Dosing and pre-mixing
Milling and dispersing (cooling)
Finishing and blending
Filling
Packaging
Frequency/Severity
1/1 3/3 2/3
2/4
2/3
2/4
4/2
2/1
2/1
Severity
1 negligible2 limited3 serious4 very serious5
catastrophic
Frequency
1practically impossible2unlikely3rarely4regularly5frequently
Transport of raw materials to company site
Transport
3/3
3/2
WasteTransport
3/3
28
Storage paintsStorage
solvents
Risk assessment and prioritisation - application
Diluting
Blending
Application
Drying
Storage of other raw material
Painted product
Continuation of manufacturing of final product
Cleaning of equipment
Frequency/Severity
Severity
1 negligible2 limited3 serious4 very serious5
catastrophic
Frequency
1practically impossible2unlikely3rarely4regularly5frequently
1/1 3/3
2/2
2/2
2/2
3/3
1/12/2
Transport 3/2
WasteTransport
3/3
29
Prioritise your hazard hotspots
3/3Application
Dosing and pre-mixing
Finishing and blending
Filling
2/4
2/4
4/2
Frequency/Severity
All others
Storage solvents 3/3
Storage solvents
Transport of raw materials to company site
3/3
3/3
WasteTransport
3/3WasteTransport
3/3
30
Tool 1.4 Map the hotspots
Step 1: Map your Hazard Hotspots
On-site
Ground plan of the company or existing company floor plan
Main areas and departments
Off-site
Plan of the region and mark your site
Identification of routes of your suppliers for delivering chemicals
Identify routes used to transport your chemical products
Locate external activity with its associated risk factor
31
Hazard hotspot map (on-site)
Storage pigments Storage solvents Storage varnishes
Storage of final paint product
Dosing and pre-mixing
Milling and dispersing (cooling)
Finishing and blending
Filling
Packaging
1/1 3/3 2/3
2/4
2/3
2/4
4/2
2/1
2/1
Transport of raw materials to company site
Transport
3/3
3/2
WasteTransport
!
!
!
!
!
3/3 !
32
Farmers, agricultural land
Road
CommunityProperties, citizens
River
Drinking water supply
Hazard hotspots map (Offsite)
Other industrial sitesWaste transport
Relevant for risk analysis!
!!Raw materials
transport
factory site (formulation)
Storage pigments
Storage
solvents
Storage varnishes
33
Tool 1.5 Legal Register
Step 1: Identify all legal, code, regulatory and other requirements that may be applicable to your products, processes and operations
Step 2: Identify all requirements present in your licenses and permits
Step 3: List all applicable requirements Step 4: Establish, schedule and assign responsibilities for updating the legal register
List of existing regulations that may be applicable to raw materials, processes and operations
National and international laws, regulations, codes of practice, customer requests and standards
34
Tool 2.1 Identify Stakeholders
Step 1: Identify Stakeholders, their relevance and importance
Step 2: Evaluate their relevance and importance
List of all stakeholders (institutions, organisations...)
Prepare ranking system
Assess each stakeholder
35
Tool 2.2 Profile Stakeholders
Step 1: Profile each stakeholder Step 2: Keep stakeholder profiles and update them after each engagement
Write down importance, current status, relationship, possible influence etc. of stakeholder
36
Tool 2.1 Identification of stakeholders
factory site
Farmer Farmer
Other industrial sites
Other factory
Road
Community
Storage fuels
Storage lubricants
Storage solvents
Storage of technical
gases
Storage acid
Waste storage
Drinking water supply
37
Involved stakeholder in the supply chain
Producer of solvents
Producer of pigments
Producer of varnishes
Producer of technical gases
Producer of fuels
Transporter (train)
Transporter (truck)
Retailer / storage
Waste disposal company
Waste storage company
Maintenance company
Community
Local authority
Insurance
companies
38
Tool 2.1 Identification of stakeholders
Tool 2.2 Profiling stakeholders
What is their knowledge of the chemical hazards posed by your
products and operations?
How important is this group to you?
Can they exert influence on your
operations?
What is the status of your existing
relationship with this stakeholder
group?
Transporter (train)
Transporter (truck)
Retailer / storage
Waste disposal company
Waste storage company
Maintenance company
Importance of stakeholder:
1= limited influence on your operation
2= influence on what you do
3= influence how you run your business & success as a business
4= significant impact on how you run your business and success as a business
39
The final stretch......
Prepare a legal register
for
formulation and application of paints including
Standards, Codes, Laws and Regulations
Schedule with responsibilities
And
Select Relevant Stakeholders
..........
40
Legal register
Products / processes and operations
Standards, Codes, Laws and Regulations
Requirements present in licenses and permits
Next check Responsible
Diluting
Cleaning
Applying
.........
41
41
Prioritisation of stakeholder issues
Stakeholders Relevant Why are they
important
How important
(1 to 4)Yes No
Suppliers of chemicalsSupplier of equipmentLocal authoritiesGovernmentCommunity groups (mayors of surrounding villages)NGOsEmployeesTransportersPartners/ joint venturesInvestorsTrade UnionsInsuranceRetailersIndustrial neighbours…
1 = they can only have
a very limited
influence on how
you run your
business
2 = they can influence
what you do and
how you do it in
certain areas of your
business
3 = they can have an
influence both on
how you run your
business and your
success as a
business
4 = they can have
significant impact on
how you run your
business and your
success as a
business
42
Tool 3.1Identify actions for risk reduction
Tool 3.2Risk reduction cost analysis
Tool 3.3Set goals, objectives, targets and indicators
Tool 3.4Chemical control action plan
Tool 3.5Training plan
Tool 3.6Emergencies plan
Tool 3.7 to 3.11Prevent and reduce risk (per activity)
Tool 3.12Business case
Tools for the third step of Responsible Production
43
Tool 3.2 Prevention and risk reduction cost analysis
Step 1: Identify costs and savings (related to chemical safety initiatives)
For each preventive or risk reduction action identified earlier, list the following costs and savings
One time capital cost
Ongoing operating cost (per year)
One time capital saving
Ongoing operating saving (per year)
Appropriate containments for spills
Temperature control in mixing vessel with automatic switch-off function
Overflow control
Locked storage for solvents
Smoking prohibited in all rooms with handling or storage of solvents
Appropriate containments for spills
Temperature control in mixing vessel with automatic switch-off function
......
44
Practical example: Risk reduction cost analysis II
Possible maximum loss (severity):
Probability for annual accident
Cost of measure
Reduced probability
Added value
45
For the brave......
Prepare a cost analysis for prevention and risk reduction
for
formulation and application of paints
including
Return on investment
Costs for various accident scenarios
..........
46
Feedback on case based exercise